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Presented by Martin Jarrett, Director, Operational Excellence and Technology, November 30 at ALUMINIUM 2016.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
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Use StMMA-FD instead of EPS for lost foam casting processJong Wu
With 20+ years experience in white side of lost foam casting, Castchem developed a new product in 2016 for pattern making in white side- StMMA-FD. To compare with the EPS, what is the advantage of the StMMA-FD? Please read my article.
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Constellium presented its new generation of high-strength Crash Management Systems at Automotive Engineering Expo 2015. Lionel Chapis, Managing Director of Automotive Structures at Constellium, and Frank Gensty, Director Engineering, Automotive Structures and Industry at Constellium, highlighted how the latest generation of aluminium Crash Management Systems is setting new industry standards.
Few players in our industry invest in a real R&D center at all, and at a significant and critical size. We continue to believe Al is the ideal solution for many markets.
To remain a material of choice, more innovation around Al is required, both incrementally and with breakthroughs.
C-TEC is the engine to deliver on this innovation.
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Need for innovative aluminium lightweight solutions - Market growth of aluminium sheet & extrusion - Driving innovation in the Constellium University Technology Center
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Volvo Cars hyllade koncept Made by Sweden ska sälja in både Volvo-bilar och Volvo-jobb på en global arena. Hur bilvarumärket och arbetsgivarvarumärket samspelar berättar Elisabeth Ed Widegren, Director Global Talent Acquisition och Louise Ahlström, Manager Communication Planning.
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Find out more at:
https://www.solberg.se/brandinwest
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Fatigue and fracture behavior of additively manufactured metals after heat tr...TAV VACUUM FURNACES
Additive Manufacturing (AM) is any of various processes of making three-dimensional solid objects from a digital file.
Unlike subtractive manufacturing methods that start with a solid block of material and then cut away the excess to create a finished part, additive manufacturing builds up a part (or features onto parts) layer by layer from geometry described in a 3D design model.
For many decades, AM processes have been used for rapid prototyping. Over the last few years, additive manufacturing has gained incredible interest in all industry facets: from aerospace applications to simple one-off consumer home builds. This technology has immense versatility and flexibility, due to its ability to create complex geometries with customizable material properties.
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Constellium supports transportation manufacturers beyond a traditional supplier role, producing value-added products and solutions and managing complex supply chains.
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Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
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1. Accelerating the Development of
Aluminium Lightweighting Solutions
for Body-In-White and
Crash Management Systems
Martin Jarrett
Aluminium 2016
November 30 , 2016
2. Agenda
Need for innovative aluminium lightweight solutions
Market growth of aluminium extrusion
Driving innovation in the Constellium University Technology Center
Conclusion
2
3. The lightweighting agenda, driven by regulation
Source: EAA Aluminium penetration in cars, Final Report, March 13, 2012, Public version
3
4. Source: 2025 CO2 Regulation. The next step to tackling transport emissions. Transport & Environment. May 2015.
The challenge is even greater
The lightweighting agenda, driven by regulation
4
5. Estimated growth in extruded & forged
aluminium products
Wrought aluminium content increasing from 140 kg in 2012, 180 kg in 2020*
14% of the wrought aluminium content used as extruded & forged product*
2025 assumes 200 kg of wrought aluminium content, 16% as extruded/forged and a
vehicle forecast of 20.5 million**
How does this translate to structural components?
*Ducker 2012 – EAA aluminium penetration in cars – **IHS Automotive 2015 – Trends in European light vehicle production
5
Average Kg’s per vehicle
6. Role of innovation in growth
From fundamental principles to technology implementation
6
Technology Scale Up & Fabrication Strategies
Liquid Metal Processing
Billet Technology
Break Through
Technologies
Industrialisation & Technology Transfer
Extrusion Process Technology
Metallurgy & Microstructural design
Surface Engineering
& Corrosion science
Engineering Design/FE Modelling
& Simulation
Technology Demonstrators
Innovation
Strategies
Engineering Centres Gottmadingen &
Van Buren
Constellium UTC – Brunel University
Phase 1 - AMCC 1
HSA6 CMS HSA6 Forgings
Extrusion - Singen CMS - Gottmadingen
7. Development & implementation strategy
Lightweighting using extrusions and forged products made from a
range of novel high performance 6xxx alloys and production
processes
Constellium University Technology Center (UTC) in partnership with
Brunel University London will provide:
Reduced development times by at least 50%
Closed loop recycling & alloy compatibility with the main sheet products
A “copy & paste” approach to industrialization, to de-risk technology transfer
A dedicated team of 15 researchers, engineers and technicians
Sponsorship of research fellows/PhD’s & training of our own engineers/technicians
The full innovation value chain
7
8. Constellium University Technology Center
Brunel University London
DC casting – alloy development & casting technology
6” and 7’ hot top billet DC caster
2m long log capability
Double drop capacity with one furnace charge
Compatible with Brunel University melt conditioning technology
8
9. Extrusion – thermo-mechanical processing & extrusion design
16MN extrusion press with puller
6” and 7” container diameter
Air, spray and standing wave quench box
14m cooling table with stretcher cold saw
Constellium University Technology Center
Brunel University London
9
10. Linking the strategic automotive alloy portfolio to
component manufacture
High Performance
Crush
C26 to C28, C3….
High Performance
Structural Body
C20 to C24
Ultra High
Strength >400 MPa
6xxx Bumpers
Ultra High
Strength >460 MPa
6xxx Forgings
Cost Competitive Solutions
Robust Manufacturing Processes
Meets Specification/Quality Standards
High Strength,
Corrosion Resistance &
Good Ductility
Excellent Crush & Corrosion
ne
Key Enablers Casting & Extrusion
Alloy & Microstructural Design
Process Design & Innovation - Casting & Extrusion Practice
Die Design – Shape, Section Complexity & Tolerances
Thermo-mechanical Processing
Key Enablers – Component Manufacture
Design Methodologies/Systems - To Provide Efficient Part Design
Process Design & Innovation – Fabrication & Joining Technologies
10
11. Lightweighting with Constellium’s new HSA6 & C2x Alloys
High-strength (HSA6)
Main loadcase:
Bending stiffness
Example:
Sill
Proof strength comparison:
AA6082: 260 MPa
HSA6: 350 Mpa
Weight save @ same
bending stiffness:
>30%
Weight saving potential for high strength & crash applications
11
Crash (C2x)
Main loadcase:
Average crash force
Example:
Crashbox
Proof strength comparison:
AA6060: 200 MPa
C27: 270 Mpa
Weight save @ same
average crash force:
>15%
13. Process control to meet crash requirements – quench
0%
20%
40%
60%
80%
100%
120%
140%
160%
180 200 220 240 260 280 300 320 340 360
TrueFractureStrain
UTS (MPa)
High Intesity
Spray
quench
Spray
quench
Air
quench
6082
True Fracture Strain
Grain Boundary Precipitate Structure
On Press Quenched 6061 In The T4
Condition
Importance of Quench Rate
14. Design for crush
Provide a “design guide” in order to optimize both alloy selection (strength &
ductility) and the geometrical features of the crush component to provide a
crash absorbing structure at the desired weight and functional performance
A methodology to link the crush performance to material ductility and profile
design has been developed.
Key process & geometrical features to provide class A crush performance
are being investigated.
Aramis (Image) Correlation
System) for deformation
measurement
Bending angle (perd. ED)
Majorstrainonfolds(Aramis)
11010090807060
56,00%
54,00%
52,00%
50,00%
48,00%
46,00%
44,00%
42,00%
40,00%
>
–
–
–
–
< 5
5 10
10 15
15 17
17 20
20
index
Crush
Crush performance =
material ductility + crush box design
Three-point bending test
Key laboratory tests to
quantify material ductility
14
17. Design & Weight
RCAR bumper, 10 kph Distance
beam to radiator
RCAR structure, 16 kph:
Max. Intrusion, Max peak force crashbox
LEAAST – Innovate UK supported research program
Optimization of front CMS by introducing Constellium’s HSA6 and C28 alloys
BenchmarkCase
seriesdesign
HSA6&C28
alloyswelded
CAD design and joining optimization
Weight saving of the fully assembled CMS of 30%
Better performance in different crash scenarios (FEA simulations)
17
18. Stretching & roll forming
Free-form bending
Magnetic pulse forming & welding
Fusion welding cell – conventional MIG to
CMT
Riveting & bonding
GOM & ARAMIS systems for dimensional
characterisation & strain measurement
Multi-axial fatigue rig to test full-size
chassis & sub-frame parts
Simple machine shop,
turning/milling/drilling/sawing (incl. mitre
cut)
Advanced Metals Processing Center
Constellium University Technology Center
Brunel University London
18
19. Advanced processing of HSA6 for higher strength
Develop the strongest 6xxx series automotive
alloys on the market & reach highest possible
strength
Apply advanced processing (TMA) to HSA6
for further 15% CMS lightweighting vs
conventional HSA6 solutions
Design CMS superior to that of conventional
6xxx & 7xxx series alloys
Optimize 6xxx composition and combine with
novel forming technics
Develop full-scale prototype components for
validation using the Constellium UTC facilities
19
20. Joining of high-strength extrusions by
Cold Metal Transfer (CMT)
HSA6 welded in the as-extruded (T4) condition then subsequently
peak-aged (T6), shows a significant improvement in HAZ strength
properties compared with material aged to T6 then welded. This effect
is more pronounced with CMT.
At equivalent weld penetration, the CMT welding process injects
significantly less heat than traditional MIG arc welding.
PWHT: Post-Weld Heat Treatment
PB: Paint bake
20
21. 60
70
80
90
100
110
120
130
MicroHardness(Hv0.1)
Hardness Through Tickness Of
Final Assembly
Interface
Between
Alloys
AA6082
AA6008
Pulse magnetic forming & welding
Technology
High rate current discharge in a coil
Shaping or joining of aluminium
Forming & welding of 6xxx automotive alloys
Locally shape & calibrate profiles (deep drawing)
Get rid of HAZ to access full strength of the
materials
Join dissimilar materials
AA6082
AA6008
Welding of aluminium
coupons
No visible interface
between materials
No hardness loss in the
alloys (i.e. no HAZ)
AA6082
AA6008
21
22. Conclusion
Stronger, more ductile aluminium alloys have a crucial role to play
in vehicle lightweighting in all products forms
Innovation-led rapid prototyping at “scale” is essential in reducing
time to market and de-risking technology transfer
Constellium University Technology Center provides industry-first capability
Investment in people to support technology delivery within R&D
units and production facilities is vital.
22